This is an update to a few other various posts made on this forum regarding noisy clutches on the 2004 Outty. The specific noise is one that almost sounds like a dry bearing or something out of balance at certain RPMs. It is a vibrating/metallic sound and it is very prevalent at 10-15mph. It is loud enough that people riding with you will hear it even with helmets on.

Well the good news is that I opened a problem file with Bomb customer support and they are going to work with the dealer to try to correct the noisy clutch. They have already replaced the clutch and it didn't correct the problem so it may not even be in the clutch.

The bad news is that they claim that they have had no other files opened from other Outty owners so they do not know what the issue is. I know that this is not an isolated case because have read comments here on this forum and I have also started two other brand new Outtys at the dealer and they made the same noise. The belt drive systems will always have a little whine to them and this is normal. This is a metalic like chatter noisethat I am referring to.

If you have an Outty that has these characteristics PLEASE call Bombardier customer support at 715-848-4957 to open a case number. They are willing to listen work with customers on this but if more customers call with the same problem I am sure that it will get elevated to a higher priority.

Also post here to indicate that you have opened a file with them.
I will post a follow up when/if my problem is resolved.

FYI:

The technician at the dealer told me yesterday afternoon that he only sees these symptoms on the Outty Max; not the one-up Outlander.

lol @ Bombardier

when the brake pad and VR issues first hit, and there were hundreds of posts about people complaining to their dealers, Bombardier claimed "...that they have had no other files opened from other Outlander owners so they do not know what the issue is..." - must be a standard response from CS

11/24/03 UPDATE ---

I picked up my Outty from the dealer this past weekend and I believe that they have solved the noise problem. What seemed to be clutch noise was actually something else. They swapped out the clutches and the noise still remained at certain RPMs. They then removed the clutch and ran the engine and it still made a rattling noise. This ruled out the clutch system entirely.

Investigation reveals that it was the exhaust pipe rattling against a metal hanger bracket. On the Outty Max if you take off the right-front plastic cover you can see a metal bracket that is supposed to stabilize the exhaust pipe. Mine didn't have the heat resistant material around it to absorb the vibration and it was missing a spring that wraps around the pipe and bracket which allowed the pipe to vibrate against the bracket at certain RPMs. It was a simple fix that took longer to detect than to actually correct.

I suspect that some of you other Outty owners chasing down a 'suspected' clutch noise issue may want to pop off your plastic covers and look at your exhaust pipe hangers.
Good luck.

My Outlander max has this noise too. I never gave it much thought, just assuming that it was a heat shield of some kind. I actually had the 2 6mm bolts that hold on the exhaust cover come right out on their own causing the shield to rotate and get pinched in the rear right shock. The bike is brand friggin new!! How does that happen? Anyway I got 2 new bolts and 4 new clips for the smaller shield and tightened it all up and it still makes the same rattling noise from 10 to 20 kms and hour. I am going to call Bomb on this one like LIL suggested.

Mac - If you pull the right side plastic cover off of your Outlander I'll bet you one warm beer that you will see the exhaust pipe passing through the hanger bracket without the heat shielding material and possibly without the spring that wraps around the pipe holding it tight against the bracket.

LIL..

I actually checked it out on my outty.. and well all parts are their but I noticed something, once the seat is removed and you just play with the write side cover it bangs against the exhaust pipe that actually makes a vibrating noise so image with a bit of throttle to me it will probly make a vibration sometimes not always on mine my toes gets kind of knumb cause of the vibration....